Modular utility cart

ABSTRACT

A modular utility cart comprising a body defining a door opening; wheels attached to a lower portion of the body for supporting the body; and a door operatively attached to the body and adapted to mate with the door opening, wherein the body is adapted to receive a utility module thereto is provided. A method of assembling a modular utility cart is also provided. A kit of utility cart and utility module(s) is equally provided herein.

CROSS-REFERENCE

The present invention relates to and claims priority from U.S.Provisional Patent Application No. 61/120,477, filed Dec. 7, 2008,entitled GALLEY CART and from U.S. Provisional Patent Application No.61/120,502, filed Dec. 8, 2008, entitled GALLEY CART PROCESS, which areincorporated herein by reference.

FIELD OF THE INVENTION

This invention relates generally to a utility cart for moving objects.More precisely, the present invention relates to a modular utility cart.

BACKGROUND OF THE INVENTION

Utility carts are used in the transport industry to perform differenttasks. They must carry goods and be configured to serve drinks, food,sell goods and collect garbage, among other tasks, along galleys. Legacygalley carts are provided with a unique planar upper surface that ismore or less suitable for performing each task. However, it is desirableto have a galley cart that can be adapted for performing specific tasks.

The improved adaptation of a galley cart for a precise task can becomean expensive and tedious process. Customizing a galley cart requires aspecific design that might be less suitable for other tasks. It istherefore likely that a greater number of galley carts are required toperform all the required tasks. The design of more “specialized carts”multiplies expensive adapted manufacturing tooling. It is thereforedesirable to reuse the parts of a cart on more than one cart design andonly change the portion dedicated to perform the specific task.

From a commercialization point of view, the specialization of galleycarts means more parts; more inventory thus more storage room. It istherefore desirable to combine existing parts to build a variety ofgalley carts configured to handle different tasks.

Additionally, the transportation industry is in quest of energyefficiency. The energy needed to move an object is mainly determine bythe following equation:

E=½m·v ²

It is well known that a mass (m) reduction will decrease the energy (E)required to move an object. Therefore, the mass of a vehicle should bereduced to improve energy efficiency of the vehicle.

Various strategies can be used to reduce the mass of a vehicle. Eitherthe mass of the vehicle itself is reduced or the mass of the object itcarries is reduced.

Airplanes are weight sensitive for obvious reasons that will not bediscussed here. Airlines are cost conscious and are in quest of reducingtheir exploitation cost. One cost reducing strategy is to use lighterparts and equipments used inside the airplane to lighten the airplane.One of these equipments is the galley cart that is used to carrypassengers' food, beverages and other goods.

However, galley carts used in aircrafts are subjected to many technicalrequirements that must be considered closely. Among others, mechanicalresistance and fire resistance requirements are mandatory and have adirect impact on the design of the galley cart and the choice ofmaterial that can be used to manufacture the galley cart.

Some galley cart uses are more restrictive than others. For instance,galley carts dedicated to be used in the aeronautic industry must complywith mandatory regulations. For example, when regulations apply to fireresistance, the material should carefully be selected and themanufacturing method needs to be adapted for the selected material.Vertical burn test (FAR 25.853), OSU heat release (65/65), smoketoxicity and smoke density are other possible requirements. It sometimeshappens that legacy-manufacturing methods are not adapted to be usedwith the material suitable to meet the technical requirements and somechallenges must be overcome to build regulation compliant cart parts.

Other energy saving considerations exist in relation with a galley cart.The thermal efficiency of the galley cart is one of them since it takesenergy to cool or heat the content of the galley cart. The saving is notmade through a mass reduction but by restricting the amount of energyrequired to cool or to warm the galley cart and, consequently, the sizeof the associated cooling or warming device. It is therefore desirableto use a material having insulation capacity thereof.

Other deficiencies will become apparent to one skilled in the art towhich the invention pertains in view of the following summary anddetailed description with its appended figures.

SUMMARY OF THE INVENTION

The following presents a simplified summary of the invention in order toprovide a basic understanding of some aspects of the invention. Thissummary is not an extensive overview of the invention. It is notintended to identify key/critical elements of the invention or todelineate the scope of the invention. Its sole purpose is to presentsome concepts of the invention in a simplified form as a prelude to themore detailed description of exemplary embodiments that is presentedlater.

Therefore, one object of the present invention improves at least some ofthe deficiencies associated with the drawbacks identified above.

It is one object of the present invention to provide a galley cartadapted to perform a plurality of tasks by changing a limited number ofparts thereof. A modular construction allows for changing only a fewparts to modify the function of the galley cart. Changing thecombination of a limited number of interchangeable parts allows forimproved flexibility while maintaining manufacturing cost reasonablylow.

It is one object of the present invention to provide a modular galleycart.

One object of the present invention provides a galley cart adapted toreceive a variety of utility modules thereon.

Another object of the present invention provides a method for buildingcustom galley cart by combining a desired arrangement of body, door andutility module together.

Another object of the present invention provides a lightweight, yetsturdy, modular galley cart.

One object of the invention provides a fire resistant modular galleycart for use in airplanes.

An object of the invention provides a modular galley cart made ofcomposite materials

Another object of the invention provides a modular galley cart made ofcomposite materials shaped in a continuous body wall.

An object of the present invention provides a modular galley cartadapted to easily receive and remove a utility module thereof.

One aspect of the present invention provides a securing mechanism on agalley cart, the securing mechanism being adapted to quickly secure autility module to the galley cart.

Another aspect of the present invention provides a variety of utilitymodules adapted to be selectively installed on a galley cart inaccordance with the intended use of the galley cart.

One other aspect of the present invention provides a module receptacledisposed either inside a body of the modular galley cart to receive autility module therein or outside the body of the galley cart to receivea utility module thereon.

An object of the invention provides a modular galley cart having amonocoque body adapted to receive an extendable tablet module therein ina first configuration and adapted to receive the extendable tabletmodule thereon in a second configuration.

Another object of the present invention provides a modular galley cartavailable in a full size configuration, adapted to define twolongitudinal openings, and available in a half size configuration,adapted to define at least one longitudinal opening; the full sizeconfiguration being adapted to accommodate two utility modules thereto.

An aspect of the invention provides a method to design a variety ofgalley carts having different features by using common parts on portionsof the galley cart that do not need to be specialized to perform theintended task and change the parts that need to be specialized toperform the intended task to minimize the number of different parts.

One aspect of the invention provides galley cart utility modules adaptedto be electrically or electronically connected to a counterpart. Thecounterpart could be a power supply disposed in the modular galley cart,embedded in a module receptacle or in the galley that docks the galleycarts. The utility module connection is adapted to send/receive dataand/or power.

One object of the invention provides a galley cart utility module havingimproved insulation properties to maintain goods therein at a desiredtemperature.

An aspect of the present invention provides a galley cart having awheelbase module adapted to support the body of the galley cart whensecured thereto.

Therefore, it is an aim of the present invention to provide an improvedgalley cart that is light, easy to manufacture and cost effective overthe existing galley cart.

A modular utility cart comprising a body defining a door opening; wheelsattached to a lower portion of the body for supporting the body; and adoor operatively attached to the body and adapted to mate with the dooropening, wherein the body is adapted to receive a utility modulethereto.

A method of building a modular utility cart, the method comprisingproviding a body; selecting a utility module; and assembling theselected utility module to the body.

A modular utility cart kit comprising a utility cart comprising a bodydefining a door opening; wheels attached to a lower portion of the bodyfor supporting the body; a door adapted to be pivotally attached to thebody and further adapted to mate with the door opening; and a utilitymodule adapted to cooperate with the body.

These and other advantages and features of the present invention willbecome apparent from the following description and the attacheddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a full size galley cart in accordancewith an embodiment of the present invention;

FIG. 2 is a perspective view of a full size galley cart in accordancewith an embodiment of the present invention;

FIG. 3 is a magnified view of a tablet module of the galley cart of FIG.1 in accordance with an embodiment of the present invention;

FIG. 4 is a perspective view of a full size galley cart with openeddoors in accordance with an embodiment of the present invention;

FIG. 5 is a front elevational view of the full size galley cart of FIG.1 in accordance with an embodiment of the present invention;

FIG. 6 is a right side elevational section view the full size galleycart of FIG. 1 in accordance with an embodiment of the presentinvention;

FIG. 7 is a perspective view of a half size galley cart in accordancewith an embodiment of the present invention;

FIG. 8 is an exploded perspective view of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 9 is an exploded perspective view of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 10 is a perspective view of a body of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 11 is a front elevational view of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 12 is a sectional top plan view of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 13 is a sectional view of a portion of a door closure mechanism ofa galley cart in accordance with an embodiment of the present invention;

FIG. 14 is a magnified view of a upper portion of a half size galleycart in accordance with an embodiment of the present invention;

FIG. 15 is a bottom plan view of a half size galley cart in accordancewith an embodiment of the present invention;

FIG. 16 is a perspective view of a body of a half size galley cart inaccordance with an embodiment of the present invention;

FIG. 17 is a rear perspective view of a body of a half size galley cartin accordance with an embodiment of the present invention;

FIG. 18 is a perspective exploded view of a body of a half size galleycart in accordance with an embodiment of the present invention;

FIG. 19 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 20 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 21 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 22 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 23 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 24 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 25 is a perspective view of a utility module in accordance with anembodiment of the present invention;

FIG. 26 is a block diagram of galley cart components in accordance withan embodiment of the present invention;

FIG. 27 is a flow chart of the selection of galley cart components inaccordance with an embodiment of the present invention;

FIG. 28 is a flow chart of the selection and connection of galley cartcomponents in accordance with an embodiment of the present invention;and

FIG. 29 is a block diagram of possible connection between variouselements of a galley cart in accordance with an embodiment of thepresent invention.

DESCRIPTION OF EMBODIMENT(S) OF THE INVENTION

The present invention is now described with reference to the drawings,wherein like reference numerals are used to refer to like elementsthroughout. In the following description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding of the present invention. It may be evident, however, thatthe present invention may be practiced without these specific details.In other instances, well-known structures and devices are shown inschematic form in order to facilitate describing the present invention.

A galley cart 10 adapted to carry goods in accordance with an embodimentof the invention is illustrated in FIG. 1. The galley cart 10 is adaptedto be used in a passenger airplane but could alternatively be used inother environments like in a passenger train or, inter alia, in themedical field. The galley cart 10 illustrated in FIG. 1 comprises a body14 defining an upper portion 18, a right lateral portion 22, a leftlateral portion 26 and a bottom portion 30. The body 14 can be describedas a monocoque construction 34 simultaneously providing the aestheticenvelope of the galley cart 10 and the structure that gives itsmechanical strength. In other words, the monocoque construction 34provides an envelope that is also the frame structure. As it will bedescribed below in respect with at least one embodiment, the monocoqueconstruction 34 uses a body 14 made of a single part.

The upper portion 18, the right lateral portion 22, the left lateralportion 26 and the bottom portion 30 of the body 14 are connectedtogether in a continuous wall. Illustrative embodiments described hereinare using radius portions 32 to interconnect adjacent portions 18, 22,26, 30. The body 14 of the illustrated embodiment forms a tubular memberhaving four planar side portions 18, 22, 26, 30 forming one part. Theside portions 18, 22, 26, 30 can be secured together in oneconfiguration while, alternatively, they can be made of a unitary partin another configuration. Both configurations can be defined as forminga monocoque structure. It can be appreciated that the wall thickness ofthe portions 18, 22, 26, 30 can have different thicknesses adapted tosustain the specific mechanical loads applied thereto. In other words,the monocoque construction 34 can be optimized to only use the requiredmaterial at the right place and therefore reducing the weight of thegalley cart 10 while providing the appropriate mechanical resistancethereto. For example, the upper portion 18 can have a thinner wallsection than the bottom portion 30 because the upper portion 18 does notbear the weight of the entire galley cart 10. Additional details aboutthe construction of the body 14 will be provided below.

The galley cart 10 illustrated in FIG. 1 is a full-size galley cart 10having a predetermined longitudinal length 34 and provided with a dooropening 38 on each longitudinal side 42, 46. Each door 50 is hingedly 52connected to body 14 and is adapted to pivot between a closed position54, when mating with its respective door opening 38, and an openposition 58 as illustrated in FIG. 4. A reinforcement member 62 recessedinto the door 50 provides support for a pulling handle 66 pivotallysecured thereon and adapted to pull the door 50. A locking member 70protruding from the door opening 38 and passing through a correspondingopening 72 in the door 50, when the door 50 is in the closed position54, to receive a lock (not shown) thereon to prevent opening of the door50 is also connected to the reinforcement member 62. A handle 74 ispivotally secured to the reinforcement member 62 to selectivelydisengage a retractable lock member 78 from a cooperating extending stem82 to open the door 50. The handle 74 can be actuated in both directionsto retract the lock member 78.

Still referring to FIG. 1, the galley cart 10 is provided with a coverelement module 90 made of moulded plastic to cover the upper portion 18of the body 14. The cover element module 90 is a portion of the galleycart 10 adapted to specialize the galley cart 10 for better performingspecific tasks while keeping the remaining portions of the galley cart10 substantially unchanged. The cover element module 90 of the presentembodiment can be permanently secured to the body 90 with glue, or thelike, to improve the shape of the upper portion 18 into a planar workingarea 94 defined by a peripherical ridge 98 configured to prevent objectsor liquids to slide off the upper portion 18 of the body 14.Alternatively, the cover element module 90 is secured via a securingelement 358.

Galley cart utility modules are portions of the galley cart 10 that canbe changed for specializing the galley cart 10 without changing thewhole galley cart 10. The module can be located at various positions onthe galley cart 10 despite the illustrative examples presented hereinare using the upper portion of the galley cart 10 to receive modulesthereto. The modularity of the present invention can be directed to thegalley cart manufacturing process by selecting the desired module at thetime of permanently assembling the galley cart. The modularity of thepresent invention can equally be directed to ongoing modification to thegalley cart 10 along its useful life by using non-permanent securingmeans to secure the module to the galley cart 10.

Continuing with FIG. 1, the bottom portion 30 rests on a wheelbasemodule 140 adapted to pivotally secure thereto four (4) sets of casterwheels 144. Two pedals 148 are also pivotally secured to the wheelbasemodule 140 to selectively lock or unlock the caster wheels 144 toimmobilize the galley cart 10.

In the present embodiment, a tablet module 110 is secured inside thebody 14, adjacent to the upper portion 18. The tablet module 110 of theillustrated embodiment comprises an extendable tablet 114 and anextendable receptacle 118. The extendable tablet 114 is moveable betweena closed position 122 and an opened position 126 as it can better beappreciated in FIG. 2. A locking mechanism 130 prevents the extendablereceptacle 118 to extend when undesired. Two handles 134 are defined inthe extendable tablet 114 and are accessible when the extendable tablet114 is slightly extended to drive the galley cart 10.

FIG. 3 is a magnified view of the tablet module 110. The semi-openeddoor 50 allows seeing the interior of the galley cart 10 where a seriesof parallel rails 160 are visible. The series of rails 160 are securedto the interior side of the lateral walls 22, 26 at a constant intervalthereto to slideably receive receptacles (not illustrated) thereon. Dryice (or means to cool) can be put in the extendable receptacle 118 tocool the interior of the galley cart 10. Openings (not visible) disposedon the lower portion of the extendable receptacle 118 are allowing coldair to pass through the extendable receptacle 118 and propagate to therest of the body 14.

FIG. 4 illustrates the full size configuration galley cart 10 with thedoors 50 in their respective opened position. Each door 50 can open in aposition parallel to an adjacent lateral wall 22, 26. For doing so, thehinge 52 is provided with a double pivot axis adapted to distance theside of the door 50 from the door opening 38 and allow parallelproximity with one of the lateral walls 22, 26.

Turning now to FIG. 5 depicting the galley cart 10 and a section linerepresenting the cut location of the section view illustrated in FIG. 6.FIG. 6 put further emphasis on the mechanical layout of the tabletmodule 110 inside the body 14. The full size galley cart 10 comprisestwo opposed tablet modules 110.1, 110.2. In other words there are twoopposed extendable tablets 114 and two extendable receptacles 118 torespectively be used on each longitudinal side 42, 46 of the full sizegalley cart 10. Each tablet module 110 has a lower wall 168 sized anddesigned to be secured on each side to the lateral portions 22, 26. Thetablet modules 110 of the present embodiment are located inside the body14 of the galley cart 10. Alternatively, the tablet modules 110 could belocated outside the body 14 on top of the upper portion 18 and coveredby an appropriate cover element module 90.

The full size galley cart 10 illustrated in FIG. 1 has a smallercounterpart. A half size galley cart 180, as illustrated in FIG. 7, hasa smaller size due to its shorter longitudinal length 34. The smallervolume of the half size galley cart 180 can contain fewer goods thereinbut allows more nimble movements.

As it is called, the half size galley cart 180 of the present embodimentis half the length of the full size galley cart 10. This is mainlyobtained by reducing the length of the body 14 and the cover elementmodule 90, by using a single tablet module 110, a single door 50 andclosing the opposite longitudinal side with a back portion 184 that canbetter be appreciated in FIG. 8. The half size galley cart 180 is shownexploded in FIG. 8. Beside the shorter longitudinal length 34 thecomponents of the half size trolley 180 are substantially similar as thecomponents of the full size trolley 10. It can be seen on exploded FIG.8 that the door 50 has a recessed portion 188 sized and designed toreceive therein the lock member 62 such that the lock member 62 and thelocking components located thereon do not extend above the externalsurface of the door 50.

FIG. 9 illustrates the half size galley cart 180 in a more detailedexploded view. Beginning from the back of the galley cart 180 it can beappreciated there is a resilient member 200 illustratively adapted tocover the rear edges 204 of the body 14. The resilient member 200 ispreferably made of a material capable of absorbing shocks, like rubberor plastic. Additional resilient members can be added on other portionsof the galley cart 180 if needed to protect the body, or other parts ofthe galley cart 180, against exterior objects that could damage thegalley cart 180. The resilient member 200 is affixed to a half sizegalley cart 180 in the present embodiment but could also be used on thefull size galley cart 10 without departing from the scope of the presentinvention.

The cover element module 90 used on a half size galley cart 180 isobviously smaller than the cover element module 90 adapted to be used inconjunction with a full size galley cart 10 as illustrated in FIG. 1.The cover element module 90 is preferably made of thermoformable orthermoset polymeric material because it is easy to shape, its low cost,its light weight and the additional features that could be added (i.e.ridges, grooves, logos . . . ). Anti-slip texture can be added on theupper surface 208 of the cover element to prevent objects to slipthereon, to help liquid to drain or to prevent undesired noise to beproduced when objects are put thereon. Similarly, a texture could beadded on the lower surface 212 to improve adhesion between the coverelement module 90, the upper portion 18 and the side portions 22, 26 ofthe body 14. This might be desirable when the cover element module 90 isglued to the body 14.

Still in FIG. 9, the tablet module 110 is extracted from the interior ofthe body 14. The extendable tablet 114 and the extendable receptacle 118are dismantled from the side guides 220 in which they operatively slidebetween their respective extended and retracted positions. Theextendable tablet 114 and/or the extendable receptacle 118 are springloaded with springs 124 located at the back of the tablet module 110 tofacilitate their extensions when they are fully retracted in the body14. A connection between one end of the spring 224 and its related sideguide 220 locates the spring in a position where the spring 224 storesenergy therein when the extendable tablet 114 and/or the extendablereceptacle 118 are retracted in the body 14. The stored energy isrestored when the locking mechanism unlocks the extendable tablet 114and/or the extendable receptacle 118 from its recessed position to pushthe tablet or the receptacle out. It is provided by the present documentto provide additional springs 224 in the tablet module 110 to preload anadditional extendable tablet 114 and/or an additional extendablereceptacle 118. Each side guide 220 is secured to the interior wallsurface of the body 14 at the appropriate height. The side guides 220 ofan embodiment of the present invention are glued to the body 14 using ornot an intervening part 228. The present embodiment uses interveningparts 228 to interface between the side guides 220 and the body 14.These additional intervening parts 228 are desirable to better locatethe side guides 220 before mounting the whole tablet module 110 in thebody 14 as opposed to trying to secure the complete tablet module 110 inthe body 14. This is very convenient, when the tablet module 110 isglued to the body 14, to glue the intervening parts 228 to the body 14and maintain it with a jig, wait for the glue to cure and then securethe remaining parts of the tablet module 110 to the body 14. Anotherembodiment of the invention (not illustrated) uses fasteners to securethe side guides 220 to the body 14 therefore allowing the side guides220 to be removed if needed. An alternate embodiment of the inventionprovides a removable securing mechanism allowing easy and quick removalof the side guides 220 to put some other features useful when the galleycart 180 is in use. A front panel 232 is located in front of the tabletmodule 110 and acts as a finishing element having an aesthetic value. Inthe present embodiment, the front panel defines an opening adapted tolet the extendable tablet 114 and/or the extendable receptacle 118 passthrough.

FIG. 9 also depicts a door opening frame 236 having a profile adapted tomate with edges of the body 14 on one side and to receive the door 50,in the closed position 54, on the other side—not illustrated in FIG. 9but illustrated in FIG. 1. The door opening frame 236 is firmly anchoredon the edge of the body 14 and is secured with an adhesive. In theillustrated embodiment the locking member 70 and the extending stem 82are moulded in the door opening frame 236 to ensure sufficient stiffnessand avoid transferring directly the load to the body 14. Alternatively,the locking member 70 and the extending stem 82 are glued to the dooropening frame 236. Another embodiment firmly secures the locking member70 and the extending stem 82 to the body 14 with fasteners and extendsthrough associated openings performed in the door opening frame 236.Additionally, the door opening frame 236 further defines a portion ofthe hinge 52 pivotally securing the door 50 to the body 14. A hingepivot 240 can be seen in FIG. 9. The long hinge pivot 240 is insertedthrough alternate openings in the door opening frame 236, the door 50and the smaller hinge members associated with reference number 52 inFIG. 9.

Turning now to FIG. 10 illustrating an isolated body 14 defining theaforementioned upper portion 18, right lateral portion 22, left lateralportion 26, bottom portion 30 and, because this is the body of a halfsize trolley 180, a back portion 184. In one embodiment, the upperportion 18, right lateral portion 22, left lateral portion 26 and bottomportion 30, interconnected with radius portions 32, are made of a singlepart and the back portion 184 is connected to the hollowed body 14afterward. This allows the hollowed body to have an extrusion-like shapebefore it is capped on one longitudinal side 42 to provide a half sizegalley cart body 14. Conversely, as explained above in reference withthe full size galley cart 10, the upper portion 18, right lateralportion 22, left lateral portion 26 and bottom portion 30 interconnectedwith radius portions 32 are forming the body 14 of the longer galleycart 10.

The upper portion 18, right lateral portion 22, left lateral portion 26,bottom portion 30 are made of composite materials to provide a strongmechanical resistance yet light weight galley cart 10, 180. Compositematerials are commonly known as a fiber reinforcement fixed with a resinmatrix. The composite material is advantageous for its lightweight; itsstructural benefits and for its thermal efficiency thus providing a goodthermal barrier between the inside of the galley cart 10 and theoutside.

The present application utilizes a liquid Phenolic resin system toinfuse dry fabrics (e.g. fibers, reinforcement material, . . . ) in thecomposite layup by means of vacuum infusion moulding. This enables toreduce the costs of materials while still enabling to mould thecomposite sandwich layup in a shape of a finished trolley. Additionally,Phenolic resin meets the safety requirement for aviation applications.

Vacuum Infusion Process (VIP) is a common resin infusion fabricationmethod usable with Phenolic resin that uses vacuum pressure to driveresin into dry fiber-reinforcement material. Materials are laid up dryinto the mold and the vacuum is applied before resin is introduced. Oncea complete vacuum is achieved, resin is literally sucked into thelaminate via carefully placed resin-feed lines. The resin infusionprocess has been identified as a cost-effective fabrication techniquefor producing damage tolerant textile composites. Dry textile preformsare resin impregnated, consolidated and cured in a single stepeliminating costly prepreg tape manufacture and ply-by-ply layup. VIPuses vacuum bag that is not reusable. The bag is placed over the partand is sealed around the perimeter of the mold with tacky-tape. Thelayup of material in the VIP consists of fiberglass woven cloth layers;a foam core; Phenolic resin and vacuum bagging accessories.

Continuing with FIG. 10, the forward edge 244 of the body 14 is shaped248 to accommodate the front panel, on its upper portion 18 and lateralportions 22, 26. Additional forms 252 are performed on the right lateralportion 26 to receive the locking member 70 and the extending stem 82 astaught in an embodiment of the invention. Other forms could be performedon the body 14 to suit various other needs without departing from thescope of the present invention.

FIG. 11 is an illustration of a half size galley cart 180 with anindication of the section area used by following FIG. 12 where it ispossible to appreciate in more details the composition of the compositematerials used in the galley cart body 14. This top plan view depictsthe continuity between the left lateral portion 26, the back portion 184and the right lateral portion 22. The radius portions 32 ensuring thecomposite wall continuity are well shown in FIG. 12 with theirrespective resilient member 200. The composite materials comprise, in anembodiment of the invention, a sandwich structure of an exteriorfinishing layer 260 used to protect the body 14 and improve itsresistance to contacts with exterior objects while giving an alternateaesthetic finish to the body 14. An exterior layer 264 of fibers andPhenolic resin comes next with a core 268 having the role of distancingthe interior layer 272 of fibers and Phenolic resin thus increasing thestiffness of the structure. An interior finishing layer 276 used toprotect the body 14 and improve its resistance to contacts with interiorobjects.

Still in reference with FIG. 12, one can appreciate that the dooropening frame 236 of the door opening 38 and the door contour frame 290are made of the same extruded material. In this embodiment of theinvention the same extruded shape is complementarily used for the dooropening frame 236 and the door contour frame 290. The use of a singleextruded shape simplifies the assembly and reduces the tooling cost. Theshape of the extrusion depicted in FIG. 13 is one workable design. Theextruded material is aluminum although other equally suitable materialcould be used and still be considered within the scope of the presentinvention (e.g. plastic).

An alternate embodiment of the interface between the door opening frame236 of the door opening 38 and the door contour frame 290 is illustratedin FIG. 13. Two different shapes of extrusion 300, 304 are used in thisembodiment and a seal 308 (an “O” ring) has been inserted in a groove312 properly sized and designed. This type of design improves thesealing of the door 50 with the body 14 to help improve thermalefficiency of the galley cart 10, 180.

Moving now to FIG. 14 illustrating a more detailed exploded view of thecover element module 90 with the upper portion 18 of the body 14. Thecover element module 90 is designed to slide fit the upper portion ofthe body 14 and be secured thereto with glue or fasteners. A recessedportion 316 having a depth equivalent to the thickness of the coverelement module 90 wall can optionally be performed in the body 14 toensure an even exterior finish to reduce the risk of hooking exteriorobjects, like cloths or seat fabric material, when the galley cart 10,180 is used. The cover element module 90 can alternatively be considereda utility module 330 in accordance with at least one embodiment as itwill be discussed later in this specification.

One embodiment of the invention providing a wheelbase 140 adapted tosecure caster wheels 144 thereon is shown in FIG. 15. The wheelbase 140,as presented by the present embodiment, is a rigid panel helpingdistributing the mechanical load from the body 14 to the caster wheels144. The wheelbase 140 can be glued or secured with fasteners to thebottom portion 30 of the body 14. An alternate embodiment directlysecures the caster wheels 140 to the body 14 and a reinforcement plate(not illustrated) disposed inside the body 14 adjacent to the bottomportion 30. The reinforcement plate help distributes the load to thecomplete bottom portion 30. A quick release mechanism couldalternatively be used to easily install and remove the wheelbase 140from the body 14. The quick release mechanism is a set of three groovedmembers disposed under the bottom portion 30 and configured to slidetherein the wheelbase 140. A locking mechanism is provided to preventthe wheelbase 140 to slide out of the quick release mechanism.Otherwise, the caster wheels 144 can be directly mounted to the body 14if the strength of the body 14 is sufficient. Here again, the wheelbase140 can also alternatively be considered a utility module 330 asdescribed below.

FIG. 16 and FIG. 17 are illustrating another embodiment of theinvention. The half size galley cart 180 presented herein does not havea tablet module 110 therein. The body 14 of the half size galley cart 18uses the entire volume for receiving goods therein. The door 50consequently covers the complete longitudinal opening 42 and givesaccess, when opened, to the complete internal volume of the body 14.

Turning now to FIG. 18 illustrating an alternate embodiment of a modulargalley cart 10 provided with a body 14 and a utility module 330. Theutility module 330 in accordance with embodiments of the invention isused to specialize the galley cart 10 for performing a task. The utilitymodule 330 is adapted to be removably connected to the body 14 such thatmany utility modules 330 can be used in conjunction with a single body14.

As explained in connection with the embodiment illustrated in FIG. 1,the utility module 330 can be directly connected to the body 14.Alternatively, the body 14 is equipped of a module receptacle 350 toquickly remove/connect the utility module 330 to the body 14. The modulereceptacle 350 provides a positioning element 354 and the securingelement 358 to locate the utility module 350 in respect with the body 14and to secure the utility module 350 to the body 14. The embodiment ofFIG. 18 illustrates a positioning element 354 in the shape of an edge354 on which rests the cooperating edge 362 of the utility module 350.The securing element in the embodiment of FIG. 18 is a rotating clip 366provided with a “T” shaped fastener 370 sized and design to cooperatewith slots 374 provided in the body 14. Turning 90 degree the rotatingclip 366 locks the “T” shape fastener 370 in their respectivecooperating slots 374. For example, the securing element 366 can be aquarter turn assembly fastener as illustrated in Spaenaur catalog, pageL36, L37, Spaenaur number 110-064 that can be found athttp://www.spaenaur.com/view_pdf.asp?Page=L37 with its mating member.Please note that the upper portion 18 has been removed on FIG. 18 toallow a better view of the body's 14 interior.

There are many possible utility modules 330 as illustrated in thefollowing Figures. They each have their unique configuration to providea desired set of functions. Each of these utility modules 330 is adaptedto mate with the module receptacle 350 as explained above.

FIG. 19 is a utility module provided with a longitudinally extendingworking area 378 that extends from the utility module 330 from anopening 382. The longitudinal extending working area 114 increases thesize of the planar working area 94 on one longitudinal side or on bothlongitudinal sides of the modular galley cart 10. A dry ice (or means tocool) compartment 384 is disposed under the longitudinally extendingtablet 114 to receive dry ice therein to cool the interior of themodular galley cart 10. Openings 386 disposed on the lower portion 388of the dry ice compartment 384 are allowing cold air to pass through theutility module 330 and move to the body 14. The dry ice compartment 384is also adapted to be closed such that cold is not lost outside thegalley cart 10.

FIG. 20 illustrates another exemplary utility module 330 provided with aseries of boxes 394 formed therein. Each box 394 is sized and designedto receive a desired good therein or to serve a particular function. Thenumber of boxes 394, as well as their respective size and location, canvary without departing from the scope of the present invention.Additional planar working area 94 is optionally provided with theextension of the longitudinally extending working area 378. Thisillustrative module and its components thereof can be manufactured ininjected plastic or with any other suitable material and process.

Turning now to FIG. 21 where is illustrated a utility module 330provided with two transversally extending working areas 378 extendingfrom their respective openings 382 disposed on each side of the utilitymodule 30.

FIG. 22 illustrates another utility module 330 adapted with two liquidreceiving compartments 394, 396. Each liquid receiving compartment 394,396 is respectively provided with a corresponding valve 400 adapted toserve the liquid contained in each respective liquid receivingcompartment 394, 396. Each compartment 394, 396 can optionally beprovided with an angular bottom 404 adapted to force the liquidcontained in a compartment 394, 396 toward the valve 400. In the presentsituation, there is one valve 400 on each side of the liquid receivingcompartment 394, 396 explaining why the bottom of the liquid receivingcompartment 394, 396 is angled in both directions. A top opening 408 isprovided on top of each liquid receiving compartment 394, 396 to insertliquid therein. Additionally, an electric connector 412 is provided withthe utility module 330 to power an internal heating element (notillustrated) to keep the liquid warm if desired.

The electric connector 412 generally is a connector adapted to mate witha cooperating connector (not illustrated) disposed on counterpartequipment to transfer data, power or a combination of data and energytherebetween. Alternatively, the electric connector 412 can be a dockconnector adapted to dock one module to a base dock and electricallyconnecting the module to the dock with connectors defined in the moduleand the base dock. The counterpart equipment can be a battery, a powerpack, a network hub or other connectable means providing data or powerto the utility module 330 connected therewith.

The electric connector 412 can be connected to the counterpart in thebody 14 or elsewhere. The electric connector 412 of the presentembodiment is not limited to connect to a power source counterpart andcan alternatively be connected to a data source counterpart. Both dataand power could be transmitted via the electric connector 412 ifrequired. The counterpart can also be located in a galley adapted toreceive therein one or many galley carts 10. Connectors adapted to meetthe regulations are well known in the art and won't be discussed infurther details therein.

Turning now to FIG. 23 that illustrates another alternate top module 330provided with receptacles 428 adapted to receive modular containers 424therein. A wall indentation 420 is provided on the sides of thereceptacles 428 to allow modular containers 424 with dispensing valves400 to be inserted therein. The size of the indentation 420 can vary432, 436 according to the intended purpose of each receptacle 428. Inthe present illustrating example, a liquid modular container 424 and anice modular container 422 are illustrated. These modular containers 422,424 can be insulated if required. A skilled reader could infer othertypes and shapes of modular containers 422, 424 adapted to perform otherfunctions without departing from the scope of the present invention.

FIG. 24 illustrates another utility module 330 adapted to receive trays(not shown) therein. Each opening 440 is provided with a pair of rails442 adapted to slide a tray thereon. The size of the openings 400 canvary according to their intended purpose and the rails 402 can beomitted if not required. For instance, this exemplary utility module 330allows easy access of trays without accessing the interior of the body14 of the galley cart 10 every time a tray is needed.

FIG. 25 illustrates a utility module 330 equipped with a mobile paymentdevice 446. The mobile payment device 446 can optionally be connected toa power source or a data source via the connector 412 provided with theutility module 330. The mobile payment device 446 can removable rest ona support 448 defined in the utility module 330. An extendable connector(not shown) can keep the mobile payment device 446 connected to thegalley cart 10 when remotely used by a client/passenger. A planarworking area 94 is also provided on the same utility module 330.

All the concepts of the above-described exemplary utility modules 330can be embodied differently. Other arrangements of boxes, receptacles,modular containers and extending working areas can differ from theillustrative examples provided above without departing from the scope ofthe present invention.

Referring now to FIG. 26, a person skilled in the art can appreciate agalley cart 10 schematically separated in various modules. In thepresented embodiment, the galley cart 10 comprises a utility module 330,a module receptacle 350, a body 14, a wheelbase 140 (that includes a setof wheels 144 thereof) and a door 50 of an appropriate length.

Turning now to FIG. 27 depicting a flow chart representing exemplarysteps for selecting the various components/modules required to assemblea modular galley cart 10. A body 14 is first selected 452, then thedesired utility module 330 is selected 454 and a door 50 is selected inaccordance with the location of the utility module 330 on the body 14(e.g. inside the body or outside). The next FIG. 28 is directed toexemplary steps for providing 460 a body 14 (either a full size of ahalf size body 14, 180), providing 462 a module receptacle 462,installing 464 a utility module 330 directly on the body 14 or via themodule receptacle 350 and electrically connecting 466 the utility module330 to a counterpart if required.

To emphasis a little more on the connectivity of the utility module 330with a cooperating counterpart, FIG. 29 illustrates possible connectionsamong the elements. A utility module 330 is electrically orelectronically connectable in several ways as illustrated. It can bedirectly connected 470 to the galley cart 10 or to the galley 500. Theutility module 330 can alternatively be connected to the galley 500 via480 a module receptacle 350 that is connected 482 to the galley cart 10or the galley 484, 500. A device 446 associated with the utility module330 can be directly connected 474 to the galley cart 10 or to the galley476, 500.

The description and the drawings that are presented above are meant tobe illustrative of the present invention. They are not meant to belimiting of the scope of the present invention. Modifications to theembodiments described may be made without departing from the presentinvention, the scope of which is defined by the following claims:

1. A modular utility cart comprising: a body defining a door opening;wheels attached to a lower portion of the body for supporting the body;and a door operatively attached to the body and adapted to mate with thedoor opening, wherein the body is adapted to receive a utility modulethereto.
 2. The modular utility cart of claim 1, wherein the bodyfurther comprises a module receptacle adapted to selectively secure theutility module.
 3. The modular utility cart of claim 2, wherein themodule receptacle further comprises a securing mechanism adapted tosecure the utility module with the module receptacle.
 4. The modularutility cart of claim 1, wherein the body is substantially made ofcomposite materials comprising Phenolic resin.
 5. The modular utilitycart of claim 4, wherein the composite materials comprise multiplelayers of reinforcement and resin, distanced by an intervening foam coreto increase the stiffness of the body.
 6. The modular utility cart ofclaim 1, wherein the body has a tubular shape and the utility module issubstantially located inside the tubular shape.
 7. The modular utilitycart of claim 1, wherein the body defines an upper portion and themodule receptacle is disposed adjacent to the upper portion.
 8. Themodular galley cart of claim 1, wherein the utility module furthercomprises an electrical connector adapted to electrically connect acounterpart to exchange at least one of data and power.
 9. The modularutility cart of claim 1, wherein the utility module comprises a mobilepayment device.
 10. The modular utility cart of claim 1, wherein theutility module comprises an extendable tablet.
 11. The modular galleycart of claim 1, wherein the utility module comprises a cavity adaptedto receive goods therein.
 12. The modular utility cart of claim 1,wherein the utility module comprises a reservoir adapted to containfluid therein.
 13. The modular utility cart of claim 1, wherein theutility module is insulated to prevent heat transfer from an internalportion of the utility module and the environment.
 14. A method ofbuilding a modular utility cart, the method comprising: providing abody; selecting a utility module; and assembling the selected utilitymodule to the body.
 15. The method of claim 14, wherein the body furthercomprises a module receptacle, and assembling the selected module to thebody is performed via the module receptacle.
 16. The method of claim 14,further comprising electrically connecting the utility module to acounterpart onboard the utility cart.
 17. The method of claim 14,further comprising electrically connecting the utility module to agalley adapted to receive the utility cart.
 18. The method of claim 14,wherein the body comprises an upper portion, a lower portion and twoopposed lateral portions respectively disposed between the upper and thebottom portions, at least some of the portions being interconnected withintervening curved portions to form a substantially continuous wallthereof, the body defining at least one longitudinal opening thereof,wherein assembling the selected utility module to the body is assemblingthe utility module at one of an internal position inside the body and anexternal position outside the body, the method further comprisingproviding one of a short door, when the utility module is secured insidethe body, and a long door, when the utility module is secured outsidethe body, the short door being adapted to substantially close thelongitudinal opening and allow access to the utility module through thelongitudinal opening, the long door being adapted to substantially closethe longitudinal opening.
 19. A modular utility cart kit comprising: autility cart comprising a body defining a door opening; wheels attachedto a lower portion of the body for supporting the body; a door adaptedto be pivotally attached to the body and further adapted to mate withthe door opening; and a utility module adapted to cooperate with thebody.
 20. The modular utility cart kit of claim 19, wherein the body hasa tubular shape and is made of composite material comprising a foam coreand Phenolic resin, the body defining an upper portion, a lower portionand two opposed lateral portions respectively disposed between the upperand the bottom portions, the portions being interconnected withintervening curved portions to form a continuous wall section thereof.